Process for producing fiber molding for fiber-reinforced composite materials

Abstract

In a process for molding a fiber molding for a fiber-reinforced composite material with short fibers oriented in one direction, a slurry molding material having short fibers dispersed in a liquid is used, and pressing forces are applied to the molding material from two directions substantially perpendicular to each other within a mold, while removing the liquid.

What is claimed is: 
     
       1. A process for molding a fiber molding for a fiber-reinforced composite material, the fiber molding having a semi-annular portion, comprising a first step of pouring a slurry molding material, which comprises short fibers dispersed in a liquid, into a first mold and then applying a primary pressing force to the molding material while removing the liquid to form an intermediate product having a semi-annular portion, wherein a direction of application of the primary pressing force is established parallel to a direction of a center line of the semi-annular portion, and   a second step of placing the intermediate product into a second mold with a semi-circular float fitment being fitted in a semi-circular recess defined in the semi-annular portion of the intermediate product, and they applying a secondary pressing force to the intermediate product in a direction substantially perpendicular to the direction of the primary pressing force, while removing the liquid and permitting the float fitment to slide on the second mold, to thereby form the fiber molding comprising the semi-annular portion.   
     
     
       2. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 1, wherein the fiber molding is for use in molding a connecting rod for an internal combustion engine, and the semi-annular portion serves as a reinforcing portion for a large end provided at one end of the connecting rod. 
     
     
       3. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 1, wherein the semi-circular float fitment is placed in slide contact with the second mold at opposite semi-circular surfaces and a flat bottom surface of the float fitment, and is placed in the second mold with the flat bottom surface of the float fitment aligned with the direction of application of the secondary pressing force. 
     
     
       4. A process for molding a fiber molding for a fiber-reinforcing composite material, the fiber molding having an annular portion, comprising a first step of pouring a slurry molding material, which comprises short fibers dispersed in a liquid, into a first mold and then applying a primary pressing force to the molding material while removing the liquid to form an intermediate product having an annular portion, wherein a direction of application of the primary pressing force is established parallel to a direction of a center line of the annular portion, and   a second step of placing the intermediate product into a second mold with a circular flat fitment being fitted in a circular recess defined in the annular portion of the intermediate product, and then applying a secondary pressing force to the intermediate production a direction substantially perpendicular to the primary pressing-direction, while removing the liquid and permitting the float fitment to slide at opposite ends thereof on the second mold, to thereby form the fiber molding comprising the annular portion.   
     
     
       5. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 4, wherein the fiber molding is for use in molding a connecting rod for an internal combustion engine, and the annular portion serves as a reinforcing portion for a small end provided at one end of the connecting rod. 
     
     
       6. A process for molding a fiber molding for a fiberreinforced composite material according to claim 4, wherein the circular float fitment is placed in slide contact with the second mold at opposite circular surfaces of the float fitment and is placed in the second mold with the circular surfaces of the float fitment aligned with the direction of application of the secondary pressing force. 
     
     
       7. A process for molding a fiber molding for a fiber-reinforced composite material, the fiber molding having a semi-annular portion, comprising a first step of pouring a slurry molding material, which comprises short fibers dispersed in a liquid, into a first mold and they applying a primary pressing force to the molding material while removing the liquid to form a primary intermediate product having a semi-annular portion, wherein direction of application of the primary pressing force is established parallel to a direction of a center line of the semi-annular portion,   a second step of placing the primary intermediate product into a second mold with a semi-circular float fitment being fitted in a semi-circular recess defined in the semiannular portion of the primary intermediate product, and then applying a secondary pressing force t one of two opposite surfaces of the primary intermediate product in a direction substantially perpendicular to the direction of the primary pressing force, while removing the liquid and permitting the float fitment to slide on the second mold, thereby providing a secondary intermediate product, and   a third step of placing the secondary intermediate product into a third mold with the semi-circular float fitment fitted in the semi-circular recess of the semiannular portion of the secondary intermediate product and then applying a tertiary pressing force to the other of the two opposite surfaces of the secondary intermediate product in a direction substantially perpendicular to the direction of the primary pressing force, to thereby form the fiber molding comprising the semi-annular portion.   
     
     
       8. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 7, wherein the second and third steps are alternately repeated. 
     
     
       9. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 7 or 8, wherein the fiber molding is for use in molding a connecting rod for an internal combustion engine, and the semi-annular portion serves as a reinforcing portion for a large end provided at one end of the connecting rod. 
     
     
       10. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 7, wherein the semi-circular float fitment is placed in slide contact with the second mold at opposite semi-circular surfaces and a flat bottom surface of the float fitment, and is placed in the second mold with the flat bottom surface of the float fitment aligned with the direction of application of the secondary pressing force. 
     
     
       11. A process for molding a fiber molding for a fiber-reinforced composite material, the fiber molding having an annular portion, comprising a first step of pouring a slurry molding material, which comprises short fibers dispersed in a liquid, into a first mold and they applying a primary pressing force to the molding material while removing the liquid to form a primary intermediate product having an annular portion, wherein a direction of application of the primary pressing force is established parallel to a direction of a center line of the annular portion,   a second step of placing the primary intermediate product into a second mold with a circular float fitment being fitted in a circular recess defined in the annular portion of the primary intermediate product, and then applying a secondary pressing force to one of two opposite surfaces of the primary intermediate product in a direction substantially perpendicular to the direction of the primary pressing force, while removing the liquid and permitting the float fitment to slide at opposite ends thereof on the second mold, thereby providing a secondary intermediate product, and   a third step of placing the secondary intermediate product into a third mold with the circular float fitment being fitted in the circular recess of the annular portion in the secondary intermediate product and then applying a tertiary pressing force to the other of the two opposite surfaces of the secondary intermediate product in a direction substantially perpendicular to the direction of the primary pressing force, to thereby form the fiber molding comprising the annular portion.   
     
     
       12. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 11, wherein the second and third steps are alternately repeated. 
     
     
       13. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 11 or 12, wherein the fiber molding is for use in molding a connecting rod for an internal combustion engine, and the annular portion serves as a reinforcing portion for a small end provided at one end of the connecting rod. 
     
     
       14. A process for molding a fiber molding for a fiber-reinforced composite material according to claim 11, wherein the circular float fitment is placed in slide contact with the second mold at opposite circular surfaces of the float fitment, and is placed in the second mold with the circular surfaces of the float fitment aligned with the direction of application of the secondary pressing force.